2010 manual illustrated parts 1000 trv cruiser eft.pdf24 2506-955 1 bracket, backrest support. 2010...

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Model Number A2010TCW4EETI (Desert Red)(Engine Serial Number: 0950TB0010060 and Up)

Illustrated PartsManual2010

1000 Cruiser EFT

NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not tobe used for assembly. For assembly procedures, use an Arctic Cat Service Manual. For a complete list of related items,refer to the current accessory catalog.

©2010 Arctic Cat Inc. Printed March 2010®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

TABLE OF CONTENTS2010 ATV 1000 Cruiser EFT

Desert Red (Model No. A2010TCW4EETI)(Engine Serial Number: 0905TB0010060 and Up)

FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES .......................................................................... 1REAR RACK, BODY PANEL, AND FOOTWELL ASSEMBLIES ............................................................................. 2FRAME AND RELATED PARTS ............................................................................................................................. 3WINCH ASSEMBLY ................................................................................................................................................ 4LICENSE PLATE HOLDER ASSEMBLY ................................................................................................................. 5SEAT ASSEMBLY ................................................................................................................................................... 6PASSENGER SEAT AND BACKREST ASSEMBLY ................ ............................................................................... 7STORAGE BOX ASSEMBLY .................................................................................................................................. 8STEERING ASSEMBLY .......................................................................................................................................... 9HANDLEBAR ASSEMBLY ..................................................................................................................................... 10INSTRUMENT POD ASSEMBLY .......................................................................................................................... 11WINDSHIELD ASSEMBLY .................................................................................................................................... 12FRONT SUSPENSION ASSEMBLY ...................................................................................................................... 13REAR SUSPENSION ASSEMBLY ........................................................................................................................ 14WHEEL AND TIRE ASSEMBLY ............................................................................................................................ 15HYDRAULIC BRAKE ASSEMBLY ......................................................................................................................... 16PARKING BRAKE ASSEMBLY ............................................................................................................................. 17GAS TANK ASSEMBLY ........................................................................................................................................ 18SHIFT LEVER ASSEMBLY ................................................................................................................................... 19AIR INTAKE ASSEMBLY ....................................................................................................................................... 20ENGINE AND EXHAUST ....................................................................................................................................... 21COOLING ASSEMBLY .......................................................................................................................................... 22CASE/BELT COOLING ASSEMBLY .............. ....................................................................................................... 23DRIVE TRAIN ASSEMBLY .................................................................................................................................... 24FRONT DRIVE GEARCASE ASSEMBLY ............................................................................................................. 25REAR DRIVE GEARCASE ASSEMBLY ................................................................................................................ 26WIRING HARNESS ASSEMBLY ........................................................................................................................... 27BATTERY AND STARTER ASSEMBLY ................................................................................................................ 28THROTTLE BODY ASSEMBLY ............................................................................................................................ 29CYLINDER ASSEMBLY ........................................................................................................................................ 30CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY .................................................................................... 31CAM CHAIN ASSEMBLY ...................................................................................................................................... 32CRANKCASE ASSEMBLY .................................................................................................................................... 33CRANKSHAFT AND PISTON ASSEMBLY ........................................................................................................... 34STARTER CLUTCH ASSEMBLY .......................................................................................................................... 35OIL PUMP ASSEMBLY ......................................................................................................................................... 36WATER PUMP ASSEMBLY .................................................................................................................................. 37TRANSMISSION ASSEMBLY ............................................................................................................................... 38SECONDARY TRANSMISSION ASSEMBLY ........................................................................................................ 39GEAR SHIFTING ASSEMBLY ............................................................................................................................... 40SECONDARY DRIVE ASSEMBLY ........................................................................................................................ 41MAGNETO ASSEMBLY ........................................................................................................................................ 42MAGNETO SIDE ENGINE COVERS ..................................................................................................................... 43CLUTCH SIDE ENGINE COVERS ........................................................................................................................ 44

2010 ATV 1000 Cruiser EFT

1

Ref Part No. Qty DescriptionNew Ref Part No. Qty DescriptionNew

FRONT RACK, BODY PANEL, AND HEADLIGHT ASSEMBLIES0745-018

1 2506-106 1 Rack, Front - Assembly (inc. 2-3)2 0411-576 1 Decal, Warning - Load3 0441-592 4 Bushing4 8410-830 4 Screw, Cap5 0423-669 4 Spacer6 0423-465 4 Grommet7 8432-802 4 Nut, Lock8 0423-654 2 Screw, Shoulder9 8050-222 2 Washer

10 0423-540 2 Nut, Lock11 0509-036 1 Headlight Assembly - Right (inc. 12-18)

0509-037 1 Headlight Assembly - Left (inc. 12-18)12 0409-102 2 Socket, Position Bulb13 0409-101 2 Bulb, Position14 0409-099 2 Bulb, Turn Signal15 0409-100 2 Socket, Turn Signal Bulb16 0409-096 2 Bulb, Headlight17 0409-097 2 Retainer, Spring18 0409-098 2 Boot, Rubber19 0423-514 2 Stud, Adjuster - Headlight20 0423-522 2 Spring, Adjuster21 0423-513 2 Knob, Adjuster22 0623-785 4 Screw, Self-Tapping

23 8050-217 8 Washer24 0423-447 4 Grommet25 2406-802 1 Panel, Side - Lower - Right

2406-803 1 Panel, Side - Lower - Left26 0423-678 8 Grommet27 1406-358 1 Cover, Access28 0423-535 2 Rivet, Reinstallable29 1406-484 1 Cover, Steering Post30 1411-050 1 Decal, “Speedrack”31 0623-362 4 Rivet, Reinstallable32 0470-513 1 Cover, Storage Box33 1406-573 1 Box, Storage34 2506-234 1 Lid, Storage Box w/Latch (inc. 35-36)35 1406-599 1 Latch, Storage Box36 0470-514 1 Lid, Storage Box37 0423-101 2 Screw, Shoulder38 2516-415 X 1 Panel, Fender - Desert Red39 0411-818 1 Decal, Reflector - Right - Amber

0411-819 1 Decal, Reflector - Left - Amber40 1411-906 1 Decal, Warning - Throttle41 1411-634 1 Decal, Side - Upper Right

1411-635 1 Decal, Side - Upper Left42 1411-725 1 Decal, Front


2

Ref Part No Qty DescriptionNewRef Part No. Qty DescriptionNew Ref Part No. Qty DescriptionNew

REAR RACK, BODY PANEL, AND FOOTWELL ASSEMBLIES0744-941

1 2516-339 1 Cover, Rack (inc. 2)2 1411-201 1 Decal, Warning - Load3 8410-640 4 Screw, Cap4 8050-223 4 Washer5 0423-891 2 Nut, Cap6 0423-540 38 Nut, Lock7 2516-169 1 Rack, Rear - Assembly (inc. 8-12)8 0441-592 4 Bushing9 0541-504 2 Pin - Assembly (inc. 10-12)

10 0423-635 2 Pin, Roll11 0423-677 2 Bushing, Flanged12 0423-636 2 Spring13 8410-835 4 Screw, Cap14 0423-669 4 Spacer15 0423-465 4 Grommet16 0423-654 2 Screw, Shoulder17 2506-092 1 Bracket, Rear Fender - Right

2506-093 1 Bracket, Rear Fender - Left18 8050-222 2 Washer19 0423-087 2 Washer20 8432-802 4 Nut, Lock

21 2516-345 X 1 Fender, Rear - Assembly - Desert Red22 1411-592 1 Decal, Reflector - Right - Red

1411-593 1 Decal, Reflector - Left - Red23 2411-176 X 1 Decal, Warning - Tire Pressure24 0423-101 2 Screw, Shoulder25 0423-419 22 Screw, Machine26 2406-042 1 Footwell, Rear - Right

2406-043 1 Footwell, Rear - Left27 8477-620 2 Screw, Machine28 2506-856 1 Footwell - Right

2506-857 1 Footwell - Left29 0423-355 8 Screw, Shoulder30 1506-125 4 Footpeg31 8476-516 6 Screw, Machine32 0409-112 1 Bezel, Taillight - Right

0409-113 1 Bezel, Taillight - Left33 3313-392 1 Taillight Assembly - Right (inc. 34-35)

3313-393 1 Taillight Assembly - Left (inc. 34-35)34 3313-506 2 Bulb, Turn Signal35 3303-849 2 Bulb, Taillight36 3304-061 6 Clip, U-Nut


3


FRAME AND RELATED PARTS0745-019

1 2506-769 1 Frame, Main2 8409-020 4 Screw, Cap3 2506-813 1 Channel, Bumper Mounting - Right

2506-285 1 Channel, Bumper Mounting - Left4 2416-162 X 1 Bracket, Support - Right

2416-163 X 1 Bracket, Support - Left5 0623-038 3 Nut w/Washer6 8477-616 2 Screw, Machine7 8477-620 1 Screw, Machine8 2406-321 1 Bracket, Mounting - Horn9 0430-053 1 Horn, Electric - 12V

10 1506-562 1 Bracket, Mounting - Bumper - Right1506-563 1 Bracket, Mounting - Bumper - Left

11 8408-816 11 Screw, Cap12 1506-855 1 Bumper13 1406-360 1 Fascia, Bumper14 0423-419 2 Screw, Machine15 0423-101 12 Screw, Shoulder

16 2406-718 1 Panel, Belly17 8409-025 2 Screw, Cap18 1506-429 1 Brace, A-Arm19 8428-002 2 Nut, Lock20 2506-701 1 Pad, Frame21 0406-289 1 Pad, Frame22 8424-802 4 Nut23 8409-016 4 Screw, Cap24 2506-776 1 Footrest - Right

1506-849 1 Footrest - Left25 2406-788 1 Strap, Footrest - Right

2406-789 1 Strap, Footrest - Left26 2506-447 1 Bracket, Support27 1411-077 1 Decal, Warning - Towing28 0541-766 1 Mount, Ball Hitch (inc. 29-30)29 0423-690 1 Nut, Lock30 0423-693 1 Screw, Cap


4


WINCH ASSEMBLY0744-933

1 1441-657 1 Winch (inc. 2-3)2 1411-826 1 Decal, Warning3 0441-061 1 Cable, Winch4 8051-246 4 Washer, Lock5 8408-820 4 Screw, Cap6 0441-403 1 Roller, Winch (inc. 7)7 0411-474 1 Decal, Warning - Pinch Point8 8468-820 2 Screw, Machine9 0541-760 1 Hook, Winch w/Strap

10 1441-129 1 Pin, Cotter11 1441-130 1 Pin12 0645-019 3 Boot, Terminal13 0623-038 6 Nut w/Washer14 0445-068 1 Cable, Winch/Solenoid - Yellow

15 0445-069 1 Cable, Winch/Solenoid - Blue16 0445-087 X 1 Cable, Solenoid/Battery - Red17 1441-112 1 Cable, Solenoid/Battery - Black18 0409-066 1 Solenoid19 8476-625 2 Screw, Machine20 0505-552 1 Switch, Winch - Assembly (inc. 21-26)21 1441-428 1 Connector, Harness22 0505-551 1 Bracket, Winch Switch23 8052-093 2 Washer, Internal Tooth Lock24 8009-243 2 Screw, Machine25 8053-212 1 Washer, External Tooth Lock26 0486-276 1 Harness, Adapter - Solenoid27 0123-788 AR Tie, Cable - 8 in.

0123-903 AR Tie, Cable - 11.5 in.


5


LICENSE PLATE HOLDER ASSEMBLY0743-236

1 2506-914 1 Mount, License Plate2 3304-772 1 Light, License Plate Assembly (inc. 3-4)3 – 2 Screw, Self-Tapping - Not a Service

Part4 3303-847 1 Bulb

5 0123-950 2 Screw, Self-Tapping6 8432-802 2 Nut, Lock7 8050-247 2 Washer8 8468-820 2 Screw, Machine


6


SEAT ASSEMBLY0744-621

1 2506-384 1 Seat Assembly (inc. 2-9)2 2506-756 1 Cover, Seat3 2506-755 1 Foam, Seat4 2406-525 1 Base, Seat - Assembly (inc. 5-6)5 0406-879 2 Bumper, Seat - Rear

6 0406-877 4 Bumper, Seat - Front7 0624-528 AR Staple8 1406-592 1 Spring, Seat Latch9 1506-156 1 Latch, Seat

10 0441-587 1 Wrench, Spanner


7


PASSENGER SEAT AND BACKREST ASSEMBLY0744-688

1 2506-938 1 Seat, Passenger - Assembly (inc. 2-19)2 2506-940 1 Seat, Passenger - Sub-Assembly

(inc. 3-6)3 2506-944 1 Cover, Seat - Passenger4 2506-942 1 Foam, Seat - Passenger5 2406-110 1 Base, Seat - Inner6 0624-263 AR Staple7 2406-044 1 Base, Seat - Passenger8 0411-814 1 Decal, “Arctic Cat”9 2406-744 1 Handhold, Passenger - Right

2406-745 1 Handhold, Passenger - Left10 8432-802 6 Nut, Lock11 8468-830 6 Screw, Machine

12 0409-126 1 Switch, Handwarmer13 2416-042 1 Cover, Switch14 0423-342 2 Screw, Self-Tapping15 0486-318 1 Harness, Adapter - Handwarmer16 2516-040 1 Bracket, Seat Support - Assembly17 2406-895 2 End Cap, Seat Support18 0423-538 2 Screw, Self-Tapping19 8427-602 4 Nut, Lock20 2506-806 1 Backrest Assembly (inc. 21-22)21 2406-765 1 Foam, Backrest22 2406-768 1 Cover, Backrest23 8408-816 8 Screw, Cap24 2506-955 1 Bracket, Backrest Support


8


STORAGE BOX ASSEMBLY0744-644

1 2516-961 X 1 Box, Storage - Assembly - Desert Red (inc. 2-24)

2 2516-510 X 1 Lid, Storage Box - Desert Red3 1411-725 1 Decal, “Arctic Cat”4 2406-787 1 Seal, Storage Box Lid5 2516-508 X 1 Top, Storage Box - Desert Red6 2406-793 1 Seal, Storage Box Top7 2516-533 X 1 Bottom, Storage Box (inc. 8)8 1411-877 1 Decal, Warning - Storage Box9 2416-209 X 1 Latch, Storage Box Lid

10 0423-901 8 Nut, Cap11 2516-117 2 Plate, Retaining12 0423-895 8 Bolt, Carriage13 2516-116 2 Plate, Retaining14 0423-355 2 Screw, Shoulder

15 2416-198 X 1 Support, Lid16 0423-540 6 Nut, Lock17 2516-511 X 1 Bracket, Mounting - Lid Support18 8477-620 5 Screw, Machine19 2416-194 X 1 Bracket, Support - Hinge - Right

2416-195 X 1 Bracket, Support - Hinge - Left20 0423-505 2 Screw, Shoulder21 8432-802 2 Nut, Lock22 2516-514 1 Hinge, Lid23 8477-616 10 Screw, Machine24 2516-555 X 1 Brace, Lid - Storage Box25 0423-889 10 Screw, Machine26 2406-843 4 Plug27 2506-926 1 Bracket, Mounting - Safety Flag


9


STEERING ASSEMBLY0743-209

1 8408-860 4 Screw, Cap2 0405-035 4 Cap, Steering Adjuster3 0423-505 2 Screw, Shoulder4 0505-484 1 Cap, Housing5 0405-138 1 Housing, Lower6 0405-139 1 Housing, Upper7 0505-451 1 Post, Steering8 8408-820 2 Screw, Cap9 2406-355 1 Steering Lock Assembly (inc. 10-12)

10 2506-173 1 Latch11 2406-349 1 Bracket, Mounting - Lock12 2406-354 1 Lock13 0602-233 1 Flange, Bearing14 0405-052 1 Bearing w/Inverted Oil Seal15 0423-073 1 Washer

16 8409-020 1 Screw, Cap17 0505-499 2 Tie Rod - Assembly (inc. 18-24)18 0505-511 2 End, Tie Rod - Left-Hand Thread - Kit

(inc. 19-20)19 – 2 End, Tie Rod - Left-Hand Thread -

Not a Service Part20 0423-013 2 Nut - Left-Hand Thread21 0405-281 2 Tie Rod22 0505-510 2 End, Tie Rod - Right-Hand Thread -

Kit (inc. 23-24)23 8420-002 2 Nut - Right-Hand Thread24 – 2 End, Tie Rod - Right-Hand Thread -

Not a Service Part25 0423-157 4 Nut, Lock26 0623-175 4 Pin, Cotter


10


HANDLEBAR ASSEMBLY0745-024

1 0505-522 1 Handlebar2 0405-218 2 Plug, Handlebar3 0405-147 2 Grip, Handlebar4 0405-149 2 End Cap, Handlebar5 8050-247 2 Washer6 8477-845 2 Screw, Machine7 0509-054 X 1 Case, Throttle - Assembly (inc. 8-15)8 0409-141 X 1 Cover, Throttle Case w/Switch9 3007-392 1 Screw, Cap

10 3004-447 1 Washer, Lock11 3003-030 1 Washer12 0409-133 X 1 Lever, Throttle13 3423-014 1 Screw, Machine14 3423-327 1 Nut15 3423-199 2 Screw, Machine

16 0411-966 1 Decal, Warning - Differential Lock17 2406-630 1 Mirror - Right (inc. 18-21)

2406-631 1 Mirror - Left (inc. 18-21)18 0423-985 2 Cover19 0423-986 2 Nut, Adjuster20 0423-987 2 Washer, Lock21 0423-988 2 Nut22 0409-081 1 Switch, Control - Assembly23 1411-865 1 Decal, Warning - Brake Lever Lock24 0609-800 2 Element, Handwarmer25 0441-498 1 Tube, Shrink26 0617-248 1 Pad, Insulator27 0409-134 X 1 Element, Thumbwarmer28 0123-811 AR Tie, Cable - 4 in.

0123-788 AR Tie, Cable - 8 in.


11


INSTRUMENT POD ASSEMBLY0744-650

1 0430-090 1 Switch, Ignition - Assembly (inc. 2-4)2 0430-050 1 Nut, Retaining3 0430-042 1 Key, Ignition - Y Series - Left-Side Cut

0430-043 1 Key, Ignition - Z Series - Right-Side Cut

4 0430-054 1 Cover, Key5 0505-596 X 1 Instrument Pod - Desert Red6 0641-897 1 Outlet, Accessory - 12V

7 0520-084 X 1 Gauge, LCD8 0420-065 1 Bracket, Retaining9 0423-493 2 Nut w/Washer

10 2506-470 1 Bracket, Mounting - Instrument Pod11 0423-535 2 Rivet, Reinstallable12 8611-267 1 Decal, AirCat13 1411-843 1 Decal, Instrument Pod14 0409-121 1 Switch, Handwarmer


12


WINDSHIELD ASSEMBLY0745-025

1 0405-384 X 1 Windshield2 0423-767 6 Clip, Retaining3 0505-620 X 1 Base, Windshield - Desert Red4 1411-987 1 Decal, Base - 1000 EFI5 1411-989 1 Decal, Base - “4x4”6 0405-332 1 Console - Black7 0423-950 6 Screw, Self-Tapping8 0623-562 2 Plug9 0641-897 1 Outlet, Accessory - 12V

10 0405-353 1 Cover, Flashlight11 1441-839 1 Flashlight

12 0486-319 1 Adapter, Harness - Outlet Accessory13 0405-352 2 Pin, Mounting - Tapered14 0423-949 4 Screw, Cap15 0423-948 4 Washer16 8450-128 2 Washer17 8431-803 4 Nut18 1441-624 2 Knob, Adjuster19 0405-350 2 Clamp, Handlebar20 0405-351 2 Cap, Handlebar Clamp21 8471-520 2 Screw, Machine22 8431-503 2 Nut, Lock


13


FRONT SUSPENSION ASSEMBLY0744-483

1 0403-209 2 Shock Absorber (inc. 2)2 0403-182 4 Bushing3 0403-102 2 Cam, Spring Adjuster4 0503-354 2 Spring, Suspension - Platinum5 1603-889 2 Retainer, Spring6 8409-040 4 Screw, Cap7 0423-744 10 Nut, Lock8 0503-420 X 1 A-Arm, Upper Right - Platinum

(inc. 9-12)0503-421 X 1 A-Arm, Upper Left - Platinum (inc. 9-12)

9 0403-207 X 4 Bushing10 0403-080 2 Axle11 0423-009 4 Ring, Retaining12 0405-115 4 Ball Joint13 0423-946 X 4 Screw, Self-Tapping14 1502-594 X 2 Clamp, Routing15 0423-334 2 Screw, Cap16 0503-380 1 A-Arm, Lower Right - Platinum

(inc. 17-18 and two No. 11-12)0503-381 1 A-Arm, Lower Left - Platinum

(inc. 17-18 and two No. 11-12)

17 0403-208 X 8 Bushing18 0403-214 X 4 Axle19 8409-075 4 Screw, Cap20 1502-344 1 Axle, Drive - Right (inc. 21-22)

1502-345 1 Axle, Drive - Left (inc. 21-22)21 0423-844 2 Clip, Retaining22 0436-276 2 Repair Kit, Boot23 0505-578 1 Knuckle - Assembly - Right (inc. 24-25)

0505-579 1 Knuckle - Assembly - Left (inc. 24-25)24 1402-809 2 Bearing25 0423-423 2 Ring, Retaining26 8409-030 4 Screw, Cap27 1406-034 1 Guard, Boot - Right - Black

1406-035 1 Guard, Boot - Left - Black28 0423-545 4 Screw, Shoulder


14


REAR SUSPENSION ASSEMBLY0744-446

1 0404-158 2 Shock Absorber (inc. 2-4)2 0403-182 2 Bushing3 0603-955 4 Bushing4 1603-219 2 Sleeve5 1603-889 2 Retainer, Spring6 0504-543 2 Spring, Suspension - Platinum7 0404-057 2 Cam, Spring Adjuster8 8409-050 2 Screw, Cap9 0423-744 10 Nut, Lock

10 0423-087 2 Washer11 8408-820 2 Screw, Cap12 0504-586 1 A-Arm, Rear - Upper Right - Platinum

(inc. 13-14)0504-587 1 A-Arm, Rear - Upper Left - Platinum

(inc. 13-14)13 0403-208 X 16 Bushing14 0403-214 X 8 Axle15 8409-075 8 Screw, Cap16 0504-576 1 A-Arm, Rear - Lower Right - Platinum

(inc. 13-14)0504-577 1 A-Arm, Rear - Lower Left - Platinum

(inc. 13-14)

17 1502-343 2 Axle, Drive (inc. 18-19)18 0423-845 2 Clip, Retaining19 0436-276 2 Repair Kit, Boot20 0423-545 4 Screw, Shoulder21 1406-068 1 Guard, Boot - Rear - Right - Black

1406-069 1 Guard, Boot - Rear - Left - Black22 0504-630 X 1 Knuckle, Right Rear - Assembly

(inc. 23-26)0504-551 1 Knuckle, Left Rear - Assembly

(inc. 23-26)23 0423-423 2 Ring, Retaining24 1402-809 2 Bearing25 0403-213 X 4 Axle26 0403-206 X 8 Bushing27 8409-000 4 Screw, Cap28 8428-002 4 Nut, Lock


15


WHEEL AND TIRE ASSEMBLY0743-965

1 0423-557 12 Screw, Shoulder2 1436-164 3 Disc, Brake3 1502-437 2 Hub, Wheel - Front (inc. 4)4 0402-974 16 Stud5 1502-437 2 Hub, Wheel - Rear (inc. 4)6 0423-607 4 Nut, Castle7 0423-407 4 Pin, Cotter8 1402-730 2 Wheel - Front - Aluminum

1402-731 2 Wheel - Rear - Aluminum

9 0423-618 16 Nut, Lug - Chrome10 1402-858 2 Tire - Front

1402-859 2 Tire - Rear11 0402-064 4 Stem, Valve (inc. 12)12 0402-140 4 Cap, Valve Stem13 1402-736 4 Cap, Wheel


16


HYDRAULIC BRAKE ASSEMBLY0745-026

1 1502-148 1 Hose, Brake - Assembly2 0623-038 1 Nut w/Washer3 8476-625 1 Screw, Machine4 1502-162 1 Lever, Brake5 8408-816 1 Screw, Cap6 8050-252 1 Washer7 1602-213 2 O-Ring8 1402-594 1 Hose, Brake9 1502-147 1 Brake Assembly

10 1402-377 1 Pin, Clevis11 8050-217 1 Washer12 0117-868 1 Pin, Cotter13 1402-592 1 Hose, Brake14 0423-413 5 Bolt, Banjo-Fitting15 0423-178 13 Washer, Crush16 0423-610 1 Bolt, Banjo-Fitting - Double17 0502-785 1 Spring, Brake Switch18 0502-840 1 Bracket, Switch19 8408-625 2 Screw, Cap20 8408-821 6 Screw, Cap21 1502-726 X 1 Caliper, Brake - Right Front

(inc. two No. 20 and 22-28)1502-727 X 1 Caliper, Brake - Left Front

(inc. two No. 20 and 22-28)1502-727 X 1 Caliper, Brake - Rear

(inc. two No. 20 and 22-28)

22 1436-160 1 Housing, Caliper - Assembly - Right Front (inc. two No. 20 and 23-25)

1436-161 1 Housing, Caliper - Assembly - Left Front (inc. two No. 20 and 23-25)

1436-161 1 Housing, Caliper - Assembly - Rear (inc. two No. 20 and 23-25)

23 0502-606 3 Piston/Seal Set (inc. 24)24 0502-607 3 Seal Set25 0502-609 3 Valve, Bleed26 0502-608 3 O-Ring, Guide - Set27 0502-605 3 Bracket Assembly28 1502-694 X 3 Pad, Brake - Set29 0502-914 1 Brake Assembly (inc. 30-38)30 0502-566 1 Screw, Machine - Kit31 0502-868 1 Cover, Reservoir32 0502-568 1 Screw, Machine - Kit33 0502-869 1 Clamp, Master Cylinder34 0502-704 1 Master Cylinder Assembly35 0502-866 1 Lever Assembly - Kit (inc. 36-37)36 0502-867 1 Lock, Brake Lever - Kit37 0502-580 1 Lever Pin - Kit38 0502-564 1 Switch, Brake39 1502-115 2 Clip, Brake Hose40 0123-788 AR Tie, Cable - 8 in.


17


PARKING BRAKE ASSEMBLY0743-214

1 1502-278 1 Lever, Parking Brake - Assembly (inc. 2-6)

2 1502-429 1 Lever, Parking Brake - Kit3 1502-432 1 Clamp, Handlebar - Kit4 1502-430 1 Adjuster, Thumb Nut - Kit5 1502-431 1 Lock, Parking Brake Lever - Kit

6 0487-055 1 Cable, Brake - Rear7 1502-176 1 Mechanical Brake Assembly8 1402-602 2 Pad, Brake9 8408-826 2 Screw, Cap

10 0402-379 1 Wire Form, Cable


18


GAS TANK ASSEMBLY0744-624

1 0570-308 X 1 Tank, Gas - Assembly (inc. 2-5)2 0470-438 1 Cap, Gas Tank (inc. 3)3 0109-733 1 Gasket, Gas Tank Cap4 0423-898 X 6 Screw, Self-Tapping5 2670-042 X 1 Plate, Retaining6 0570-323 X 1 Pump, Fuel - Assembly (inc. 7)7 0470-838 X 1 Seal8 0570-282 X 1 Hose, Gasline - Assembly9 0423-688 2 Clamp, Hose

10 0410-070 AR Hose, Gasline - 25 ft11 0510-335 1 Filter, In-Line12 0470-794 1 Bracket, Mounting - Filter13 0123-788 AR Tie, Cable - 8 in.14 0423-732 2 Screw, Shoulder15 0470-822 1 Shield, Heat16 0623-797 4 Screw, Self-Tapping17 0423-460 2 Grommet


19


SHIFT LEVER ASSEMBLY0745-046

1 0402-843 1 Knob, Shift2 0423-345 1 Clip, Retaining3 1402-576 1 Plate, Shift4 2406-345 1 Shield, Shift Plate5 0423-357 4 Nut, Stamped6 0502-659 1 Lever, Shift7 1502-332 1 Actuator, Shift Lever8 8424-602 1 Nut9 0402-678 1 Spring, Shift Lever

10 0423-182 2 O-Ring11 0402-675 1 Axle, Pivot12 8408-812 1 Screw, Cap

13 0423-087 1 Washer14 0423-299 2 O-Ring15 8424-802 1 Nut16 1402-621 1 Pin, Mounting - Shift Linkage17 0423-091 2 Bushing18 0623-094 2 Washer19 0423-169 2 E-Ring20 1502-227 1 Linkage, Shift - Assembly (inc. 21-23)21 0623-294 1 Nut, Hex - Right-Hand Thread22 1402-619 1 Coupler23 0123-917 1 Nut, Hex - Left-Hand Thread


20


AIR INTAKE ASSEMBLY0744-449

1 0413-091 1 Diverter, Air - Top2 0413-093 1 Diverter, Air - Bottom3 2406-509 1 Shroud, Splash4 0623-362 2 Rivet, Reinstallable5 0423-551 2 Clamp6 0423-342 4 Screw, Self-Tapping7 0413-096 1 Cap, Air Intake - Diverter8 0470-583 1 Boot, Air Intake9 0423-019 2 Clamp

10 0423-716 2 Wing Nut11 0470-832 1 Cover, Air Intake12 0470-828 1 Filter, Air13 0470-731 1 Support, Air Filter

14 0570-221 1 Housing, Air Intake15 0406-877 4 Bumper16 0470-442 2 Valve, Drain17 0470-638 1 Boot, Throttle Body18 0430-055 1 Sensor, Air Temperature (inc. 19)19 5507-224 1 O-Ring20 0623-028 6 Clamp, Hose21 0410-198 X 1 Hose, Separator Tank22 0470-718 1 Tank, Separator23 0410-196 X 1 Hose, Crankcase24 0410-208 X 1 Hose, Crankcase25 0423-066 1 Clamp


21


ENGINE AND EXHAUST0744-086

1 0800-111 X 1 Engine, A950K (inc. 2-3)2 0801-128 1 Spacer, Engine Mount3 0801-091 4 Mount, Engine4 0423-426 2 Washer5 0423-734 1 Screw, Cap6 0423-451 1 Screw, Cap7 8428-002 2 Nut, Lock8 8408-820 4 Screw, Cap9 0412-338 2 Gasket, Exhaust Pipe

10 0512-433 1 Pipe, Exhaust - Assembly (inc. 11-13)11 0512-349 1 Pipe, Exhaust12 0412-400 1 Shield, Exhaust Pipe13 0423-317 2 Clamp

14 8477-610 8 Screw, Machine15 0512-453 1 Pipe, Exhaust - Rear16 0412-484 1 Shield, Exhaust Pipe - Rear17 0412-375 2 Seal, Exhaust Pipe18 0612-668 4 Spring, Extension19 0412-215 3 Bushing20 1506-732 1 Channel, Muffler Support21 0512-355 1 Muffler - Assembly (inc. 22-24)22 8408-616 3 Screw, Cap23 0512-219 1 Arrester, Spark - Assembly24 0412-313 1 Gasket, Spark Arrester25 0412-373 1 Cover, Muffler26 0411-426 1 Decal, Warning - Clutch Cover


22


COOLING ASSEMBLY0745-017

1 0413-258 X 1 Radiator Assembly (inc. 2-13)2 0413-216 1 Radiator3 0413-255 X 1 Cap, Radiator4 1623-637 4 Clip, U-Nut5 0413-195 1 Plug, Drain6 1602-213 1 O-Ring7 0413-217 1 Bracket, Mounting - Fan8 0413-123 1 Fan, Cooling9 8470-510 12 Screw, Machine

10 0413-214 1 Screen, Radiator11 0423-351 1 Clamp, Wire12 0610-011 AR Hose - 25 ft13 0423-030 2 Grommet14 0423-484 2 Screw, Shoulder15 0623-038 4 Nut w/Washer16 0423-028 2 Bushing, Stem17 0423-496 11 Clamp, Hose18 0410-120 1 Hose, Coolant - Radiator/Thermostat -

Upper19 8470-520 4 Screw, Machine20 0808-092 1 Cover, Thermostat

21 0830-173 1 O-Ring22 0808-093 1 Thermostat23 0808-124 1 Sensor, Engine Coolant Temperature24 0808-189 X 1 Housing, Thermostat25 0410-195 X 1 Hose, Coolant - No. 226 0410-116 1 Hose, Coolant27 0410-115 1 Hose, Coolant - Crossover28 0410-117 1 Hose, Coolant - No. 129 1623-093 1 Clamp, Hose30 0410-119 1 Hose, Coolant - Lower31 0623-751 AR Tie, Cable - 11.5 in.32 0413-211 1 Cooler, Oil33 8476-612 2 Screw, Machine34 0513-022 1 Bracket, Mounting - Oil Cooler - Upper35 0423-632 4 Clamp, Hose36 0410-149 1 Hose, Oil Cooler - In37 0410-219 X 1 Hose, Oil Cooler - Out38 0413-087 1 Plug39 0413-086 1 Bottle, Overflow40 0124-045 1 Clamp, Hose41 0623-316 AR Tie, Cable - 14 in.


23


CASE/BELT COOLING ASSEMBLY0744-451

1 0413-137 1 Shroud, Air - Air In2 0413-138 1 Duct, Cooling - Air In3 0423-730 3 Clamp4 0413-139 1 Boot, Cooling - Air In5 0413-135 1 Boot, Cooling - Air Out

6 0423-019 1 Clamp7 0413-207 1 Duct, Cooling - Air Out8 0623-797 1 Screw, Self-Tapping9 0623-362 2 Rivet, Reinstallable


24


DRIVE TRAIN ASSEMBLY0744-087

1 1402-620 2 Bladder, Gearcase2 0423-315 4 Clamp, Hose3 8428-002 4 Nut, Lock4 0423-426 8 Washer5 0423-404 3 Screw, Cap6 0423-830 1 Screw, Cap7 1502-403 1 Gearcase, Rear8 0123-788 AR Tie, Cable - 8 in.9 0410-070 AR Hose, Vent - 25 ft

10 0470-702 1 Fitting, Vent11 1502-395 1 Gearcase, Front12 1502-338 1 Driveshaft, Rear - Assembly (inc. 13-17)13 1402-567 1 Yoke, Slip14 0402-944 2 Joint, Universal (inc. four No. 15)15 0423-395 8 Ring, Retaining16 1502-337 1 Driveshaft, Rear17 1402-689 1 Yoke, Flange18 8408-820 4 Screw, Cap


25


FRONT DRIVE GEARCASE ASSEMBLY0743-254

- 1502-395 1 Complete Front Drive Gearcase Assembly

1 0502-923 1 Shaft, Propeller - Assembly (inc. 2-3)2 1402-438 1 Shaft, Input3 1402-168 1 Deflector4 1402-011 1 Seal5 0423-423 1 Ring, Retaining6 1502-237 1 Bracket, Actuator7 0502-585 1 Actuator8 0423-892 1 O-Ring9 0423-396 3 Screw, Self-Tapping

10 1402-043 1 Bearing11 0423-118 11 Screw, Self-Tapping12 0502-528 1 Housing, Pinion13 0402-947 1 Gasket14 0423-417 1 Ring, Retaining15 0402-413 1 Coupler, Drive16 0402-357 1 Collar, Lock17 0502-784 1 Gear, Pinion - Assembly - 11T

(inc. 18-19)18 0402-336 1 Collar, Retaining19 0402-327 1 Bearing20 0402-328 1 Bearing21 0502-514 1 Housing, Gearcase22 0402-411 1 Pin, Dowel23 0402-999 1 Spring, Return24 0423-147 1 O-Ring25 0402-417 1 Shaft, Shuttle26 0402-998 1 Fork, Selector27 0423-402 1 Ring, Retaining28 0402-997 1 Shaft, Selector29 1402-210 1 Plug, Magnetic (inc. one No. 30)

30 0423-153 2 O-Ring31 0423-149 1 O-Ring32 0402-393 1 Bearing33 0402-405 AR Shim

0402-406 AR Shim0402-407 AR Shim0402-408 AR Shim0402-409 AR Shim

34 1502-554 1 Gear, Ring - 34T35 1402-074 AR Shim


36 1502-389 1 Cover, Gearcase (inc. one No. 30 and 37-49)

37 1402-053 1 Bearing38 0502-413 1 Flange, Bearing39 1402-079 1 Pin, Alignment40 1402-042 1 Collar, Sliding41 1402-054 1 Fork42 1402-058 2 Ring, Retaining43 1402-057 1 Spring44 1402-063 1 Spring45 1402-656 1 Shaft, Lock46 1402-104 1 Fitting47 1402-056 1 Seal48 1402-713 2 Seal49 1402-211 1 Plug, Oil Level (inc. one No. 30)50 0402-333 1 Plug, Fill (inc. 51)51 0423-154 1 O-Ring


26


REAR DRIVE GEARCASE ASSEMBLY0742-972

- 1502-403 1 Complete Rear Drive Gearcase Assembly

1 1502-317 1 Housing, Gearcase2 0402-393 2 Bearing3 1402-713 2 Seal4 1402-033 1 Gear, Ring - 34T5 0402-405 AR Shim


6 0402-326 1 Button, Thrust7 0402-429 AR Shim


8 0423-149 1 O-Ring9 1502-082 1 Cover, Gearcase

10 0402-333 1 Plug, Fill (inc. 11)11 0423-154 1 O-Ring12 1402-102 1 Fitting

13 0423-118 8 Screw, Self-Tapping14 0402-450 1 Plug, Magnetic (inc. one No. 15)15 0423-153 2 O-Ring16 1402-211 1 Plug, Oil Level (inc. one No. 15)17 0402-947 1 Gasket18 0402-411 1 Pin, Dowel19 0402-328 1 Bearing20 0502-784 1 Gear, Pinion - Assembly - 11T

(inc. 21-22)21 0402-327 1 Bearing22 0402-336 1 Collar, Retaining23 0402-331 1 Collar, Lock24 0423-834 3 Screw, Self-Tapping25 1502-284 1 Shaft, Input (inc. 26-33)26 1502-287 1 Cartridge, Clutch - Assembly27 0423-799 1 Ring, Retaining - External28 1402-682 1 Basket, Clutch29 0423-798 1 Ring, Retaining - Internal30 1402-678 1 Bearing, Flange31 1402-677 1 Bearing32 1402-687 1 Seal33 1502-285 1 Housing, Input


27


WIRING HARNESS ASSEMBLY0745-030

1 0486-355 X 1 Harness, Main (inc. 2-9)2 0486-164 1 Tether, Accessory Connector3 0430-085 X 1 Cover, Fuse Block4 0430-045 5 Relay (4-Pin) - 20 Amp5 0430-034 1 Diode6 0430-037 1 Holder, Fuse7 0430-032 6 Fuse - 10 Amp

0430-031 4 Fuse - 15 Amp0430-030 2 Fuse - 30 Amp

8 2411-081 X 1 Decal, Fuse Block9 0430-086 X 1 Seal

10 0430-049 1 Control, Turn Signal11 8476-516 1 Screw, Machine12 8427-502 1 Nut, Lock13 0423-493 2 Nut w/Washer14 0409-064 1 Switch, Tilt Sensor15 0123-802 2 Washer

16 8468-425 2 Screw, Machine17 0530-034 X 1 ECU18 0430-059 1 Cushion, ECU19 2406-728 1 Bracket, Mounting - ECU20 0423-036 2 Spacer21 8476-635 2 Screw, Machine22 0623-038 7 Nut w/Washer23 0824-037 1 Regulator, Voltage24 8476-625 2 Screw, Machine25 0824-043 2 Coil, Ignition - Assembly26 0824-049 2 Cap, Spark Plug27 8476-620 2 Screw, Machine28 8476-630 1 Screw, Machine29 0123-788 AR Tie, Cable - 8 in.

0123-903 AR Tie, Cable - 11.5 in.30 0409-089 1 Switch, Brake - Assembly


28


BATTERY AND STARTER ASSEMBLY0744-454

1 5991-655 1 Battery Cover/Tool Tray Assembly (inc. 2-4)

2 2406-815 1 Cover, Battery3 0444-122 1 Kit, Tool4 0417-016 1 Pad, Battery5 8476-620 2 Screw, Machine6 0645-480 1 Battery Assembly (inc. 7)7 0645-430 1 Decal, Warning8 0417-017 1 Foam, Battery9 0445-071 1 Cable, Battery/Ground

10 0445-062 1 Cable, Battery/Solenoid11 0645-327 1 Boot, Terminal12 0623-038 5 Nut w/Washer13 8476-630 2 Screw, Machine14 0445-066 1 Cable, Solenoid/Starter (inc. 15)15 0645-019 1 Boot, Terminal16 0445-058 1 Solenoid17 8476-625 2 Screw, Machine18 0825-015 X 1 Motor, Starter - Assembly


29


THROTTLE BODY ASSEMBLY0742-977

1 0470-686 1 Throttle - Assembly (inc. 2-15)2 – 1 Throttle Body - Not a Service Part3 0430-072 1 Sensor, Throttle Position4 5507-234 1 O-Ring, Throttle Position Sensor5 5507-231 1 Screw, Machine6 0430-074 1 Valve, ISC7 5507-233 1 O-Ring, ISC Valve8 5507-227 1 Bracket, MAP Sensor9 5507-117 2 Screw, Machine

10 0430-073 1 Sensor, MAP11 5507-232 1 O-Ring, MAP Sensor12 5507-229 1 Plate, ISC Valve13 5507-235 1 O-Ring14 5507-223 1 Cover15 5507-037 1 Screw, Machine

16 0570-230 1 Manifold, Intake - Assembly (inc. 17-26)17 0423-066 4 Clamp18 0470-660 2 Boot, Intake - Manifold19 0470-688 2 Injector, Fuel20 0470-763 1 Rail, Fuel - Front Cylinder21 0470-764 1 Rail, Fuel - Rear Cylinder22 0470-767 2 O-Ring, Fuel Injector23 0470-768 2 Ring, Seal - Fuel Injector24 0570-140 2 Manifold, Intake25 0570-156 1 Plenum, Intake26 0423-371 2 Screw, Machine27 0826-008 6 Screw, Machine28 0487-046 1 Cable, Throttle29 0830-090 2 O-Ring30 3002-964 1 Clamp, Wire


30


CYLINDER ASSEMBLY0745-047

1 0830-209 X 2 Gasket, Head2 0804-031 2 Cylinder3 0829-002 8 Pin, Dowel4 0827-002 4 Bolt, Stud5 0827-018 4 Bolt, Stud6 8424-604 8 Nut7 0830-193 X 2 Gasket, Base8 0804-037 1 Plug, Cylinder

9 0830-007 2 O-Ring10 0804-046 1 Union, Coolant Hose11 8468-612 2 Screw, Machine12 0804-030 1 Union, Coolant Hose13 8468-630 2 Screw, Machine14 0801-174 X 1 Cover, Breather15 0830-134 1 Gasket


31


CYLINDER HEAD AND CAMSHAFT/VALVE ASSEMBLY0743-989

1 0808-135 2 Head, Cylinder - Assembly (inc. 2-17)2 0829-001 4 Pin, Dowel3 0826-001 8 Screw, Cap4 0809-202 2 Arm, Valve Rocker - Intake

(inc. two No. 5-6)5 0809-033 8 Screw, Adjuster6 0827-007 8 Nut7 0809-205 2 Arm, Valve Rocker - Exhaust

(inc. two No. 5-6)8 0809-008 2 Shaft, Rocker Arm - Exhaust9 0809-007 2 Shaft, Rocker Arm - Intake

10 0809-014 16 Cotter, Valve11 0809-013 8 Retainer, Spring12 0809-138 8 Spring, Valve13 0830-016 8 Seal, Oil14 0809-006 8 Seat, Spring - Valve15 0809-040 4 Valve, Exhaust16 0809-039 4 Valve, Intake17 0831-041 4 Plug, Shaft18 0809-246 1 Camshaft, Front Cylinder

0809-248 1 Camshaft, Rear Cylinder19 0809-002 2 Sprocket

20 0826-034 4 Screw, Cap21 0828-004 2 Plate, Retainer22 0829-008 2 Pin, Dowel23 0809-003 2 C-Ring24 0808-077 2 Plug, Cylinder Head25 0826-007 12 Screw, Cap26 0808-003 4 Cap, Inspection27 0830-167 4 O-Ring28 0808-090 8 Screw, Cap29 0830-147 8 Washer30 0830-107 8 Gasket31 0826-002 4 Screw, Cap32 0826-005 4 Screw, Cap33 0826-006 4 Screw, Cap34 0217-799 2 Spark Plug - CPR8E35 0830-120 2 Seal36 0808-008 2 Cover, Thermostat37 0827-062 X 2 Bolt, Stud38 8424-804 2 Nut39 0827-030 4 Bolt, Stud40 8424-604 4 Nut


32


CAM CHAIN ASSEMBLY0745-069

1 0810-001 2 Chain, Cam2 0810-046 2 Guide, Chain3 0810-049 2 Tensioner, Chain4 0826-106 2 Pivot, Tensioner5 0810-004 2 Adjuster, Tensioner - Assembly

6 0830-134 2 Gasket7 8468-620 4 Screw, Machine8 8400-610 2 Screw, Cap9 0828-129 2 Washer


33


CRANKCASE ASSEMBLY0745-051

1 0801-172 X 1 Crankcase - Assembly (inc. 2-13)2 0830-035 1 Seal, Driveshaft3 0832-048 1 Bearing4 0832-042 1 Bearing5 0832-050 2 Bearing6 0832-049 1 Bearing7 0832-055 1 Bearing - Assembly (inc. 8)8 0832-057 1 Bearing9 0801-002 2 Plug, Engine Case

10 0822-052 1 Seal, Countershaft - Right11 0829-003 2 Pin, Dowel12 0829-002 2 Pin, Dowel13 0812-008 1 Union, Oil Filter14 0812-029 1 Filter, Oil15 0830-172 X 1 O-Ring16 0812-060 1 Fitting, Oil17 8468-620 2 Screw, Machine18 0623-914 2 Screw, Self-Tapping19 0812-079 X 1 Plate, Oil Sump20 0812-052 1 Valve, Oil-Relief - Assembly

21 0830-162 1 O-Ring, Oil Filler Cover22 0812-081 1 Cover, Oil Filler23 8468-616 3 Screw, Machine24 0801-179 X 1 Stick, Oil Level25 0830-010 1 O-Ring26 0812-078 X 1 Fitting, Oil - Threaded27 0830-191 X 1 Gasket, Breather28 0829-001 2 Pin, Dowel29 0832-084 X 1 Bearing30 0831-086 X 1 Circlip31 0801-193 X 1 Cover, Breather32 8468-625 5 Screw, Machine33 8468-630 2 Screw, Machine34 8412-875 1 Screw, Cap35 8468-660 8 Screw, Machine36 8468-640 2 Screw, Machine37 8412-830 3 Screw, Cap38 8412-860 10 Screw, Cap39 8412-850 1 Screw, Cap


34


CRANKSHAFT AND PISTON ASSEMBLY0745-070

1 0805-299 2 Piston Set - Assembly (inc. 2-4)2 0805-164 2 Ring, Piston - Set3 0805-199 4 Circlip, Piston Pin

4 0805-198 2 Pin, Piston5 0805-200 1 Crankshaft - Assembly6 0805-273 1 Washer, Thrust


35


STARTER CLUTCH ASSEMBLY0745-071

1 0815-026 X 1 Gear, Starter Idler - No. 12 0829-031 1 Shaft, Starter Gear3 0815-002 1 Gear, Starter Idler - No. 24 0815-003 1 Spacer, Starter Idler Gear No. 25 0829-032 1 Shaft, Starter Gear

6 0815-004 1 Gear, Starter Clutch (inc. 7)7 0832-079 1 Bearing8 0802-035 1 Clutch, Starter9 0826-069 6 Screw, Cap

10 0828-113 1 Washer, Wave


36


OIL PUMP ASSEMBLY0745-052

1 0812-041 1 Gerotor - Set2 0829-009 2 Pin, Dowel3 0812-048 1 O-Ring4 0812-040 1 Housing, Oil Pump5 8468-625 2 Screw, Machine6 0812-047 1 Seal, Oil Pump7 0828-007 1 Shim8 0812-046 1 Shaft, Oil Pump

9 0812-045 1 Gear, Driven10 0831-002 1 Ring, Retaining11 0812-057 1 Strainer, Oil12 0826-040 2 Screw, Machine13 0812-053 1 Cap, Oil Strainer14 8468-625 4 Screw, Machine15 0812-006 1 Plug, Drain16 0830-017 1 Gasket, Drain Plug


37


WATER PUMP ASSEMBLY0745-053

1 0813-056 X 1 Pump, Water - Assembly (inc. 2)2 0830-029 1 O-Ring3 8468-650 2 Screw, Machine4 0832-084 X 1 Bearing5 0831-086 X 1 Circlip6 0813-041 X 1 Shaft, Driven Gear7 0831-010 2 Ring, Retaining8 0813-043 X 1 Gear, Driven

9 0829-009 1 Pin, Dowel10 0831-002 1 Ring, Retaining11 0832-046 2 Bearing12 0813-028 1 Spacer, Idler - Water Pump13 0813-026 1 Shaft, Water Pump Idler Gear14 0831-004 1 Ring, Retaining15 0813-027 1 Gear, Idler - Water Pump - Drive16 0831-040 1 Ring, Retaining


38


TRANSMISSION ASSEMBLY0744-238

1 0823-157 1 Pulley, Driven - Assembly (inc. 2-4)2 0823-176 3 Shoe, Cam3 0823-177 3 Screw, Machine4 0823-178 1 Nut, Driven Pulley5 0832-010 1 Bearing6 0830-176 1 Seal7 0823-020 1 Retainer, Bearing8 0826-031 2 Screw, Machine9 0827-010 1 Nut

10 0828-106 1 Washer11 0823-008 1 Plate, Movable Drive Face12 0823-010 4 Damper, Movable Drive Face13 0823-265 1 Spacer, Movable Drive Face14 0823-170 8 Roller, Movable Drive Face15 0823-159 1 Face, Movable Drive

16 0823-231 1 Belt, Drive17 0823-156 1 Face, Fixed Drive18 0823-015 1 Spacer, Fixed Drive Face19 0470-531 1 O-Ring20 0830-188 1 Seal, Clutch Housing - Right21 0832-047 1 Bearing22 0823-261 1 Housing, Clutch23 0826-029 2 Screw, Machine24 0822-010 2 Retainer, Bearing25 0830-189 1 Seal, Clutch Housing - Left26 0827-011 1 Nut27 0823-018 1 Clutch, One-Way28 0823-098 1 Clutch, Centrifugal - 6 Plate29 0823-292 1 Spacer


39


SECONDARY TRANSMISSION ASSEMBLY0745-054

1 0822-091 1 Countershaft Assembly (inc. 2-15)2 0822-014 1 Gear Select, Reverse3 0831-011 2 Ring, Retaining4 0822-045 1 Spacer, Reverse Driven Gear5 0828-008 2 Washer6 0822-013 1 Gear, Reverse Driven7 0832-011 3 Bearing8 0822-005 3 Bushing9 0828-014 1 Washer, Lock

10 0828-015 1 Washer, Lock11 0822-004 1 Gear, Driven - Low12 0822-046 2 Washer, Driven Gear13 0822-003 1 Countershaft14 0822-007 1 Gear Select, Sliding15 0822-006 1 Gear, Driven - High16 0822-089 1 Gear, Drive17 0828-019 1 Washer, Thrust

18 0828-011 1 Washer19 0831-040 1 Ring, Retaining20 0822-050 1 Trigger, Speedometer Sensor21 0828-069 1 Washer, Thrust22 0831-039 1 Ring, Retaining23 0829-001 2 Pin, Dowel24 0830-194 X 1 Gasket25 0806-105 X 1 Housing, Speedometer Sensor26 0830-044 1 Seal27 8468-630 4 Screw, Machine28 0824-042 1 Sensor, Speedometer29 8468-620 1 Screw, Machine30 0822-001 1 Driveshaft31 0828-016 2 Washer, Thrust32 0822-011 1 Gear, Reverse Idle33 0822-012 1 Bushing34 0822-015 1 Shaft, Reverse Idle


40


GEAR SHIFTING ASSEMBLY0745-057

1 8470-516 2 Screw, Machine2 0409-091 1 Switch, Gear Position3 0818-013 2 Contact4 0818-017 2 Spring5 0828-040 1 Washer6 0818-046 1 Shaft, Gear Shift - Assembly7 0828-095 2 Washer, Thrust8 0832-052 1 Bearing, Thrust9 0818-055 1 Cam, Gear Shift

10 0826-006 1 Screw, Cap11 0828-036 1 Washer12 0831-010 1 Ring, Retaining

13 0818-095 X 1 Shaft, Sub-Gear Shift14 0818-014 1 Arm, Shift15 8468-620 1 Screw, Machine16 0828-038 1 Washer17 0818-002 1 Stopper, Cam18 0818-004 1 Support, Cam Stopper19 0818-090 1 Spring20 0828-035 1 Washer21 8424-602 1 Nut22 0818-072 2 Fork, Shift23 0818-006 1 Shaft, Shift Fork


41


SECONDARY DRIVE ASSEMBLY0745-058

1 1502-342 1 Driveshaft, Front - Assembly (inc. 2, one No. 3, four No. 4, and 5)

2 1402-701 1 Yoke, Slip3 0402-944 2 Joint, Universal - Set (inc. 4)4 0423-395 8 Ring, Retaining5 1502-341 1 Driveshaft, Front6 0827-013 2 Nut7 0828-020 2 Washer8 1502-325 1 Yoke, Propeller Shaft Joint9 0830-043 2 Seal, Oil

10 0832-017 2 Bearing11 0828-021 AR Shim, 25 x 34 x 0.25 mm

0828-022 AR Shim, 25 x 34 x 0.30 mm0828-023 AR Shim, 25 x 34 x 0.70 mm0828-024 AR Shim, 25 x 34 x 0.90 mm0828-025 AR Shim, 25 x 34 x 0.95 mm0828-026 AR Shim, 25 x 34 x 1.00 mm0828-027 AR Shim, 25 x 34 x 1.05 mm0828-028 AR Shim, 25 x 34 x 1.10 mm0828-029 AR Shim, 25 x 34 x 1.15 mm

12 0819-089 X 1 Shaft, Secondary Driven - Front13 0832-016 1 Bearing, Driven Gear14 0819-011 1 Ring, Driven Bearing15 0822-106 1 Gear, Secondary Driven16 0819-053 1 Shaft, Secondary Driven - Rear17 0819-005 1 Flange, Output Joint - Rear18 0822-108 1 Gear, Secondary Drive19 0828-119 AR Shim, 30 x 48 x 0.25 mm

0828-120 AR Shim, 30 x 48 x 0.30 mm0828-121 AR Shim, 30 x 48 x 0.35 mm0828-122 AR Shim, 30 x 48 x 0.90 mm0828-123 AR Shim, 30 x 48 x 0.95 mm0828-124 AR Shim, 30 x 48 x 1.00 mm0828-125 AR Shim, 30 x 48 x 1.05 mm0828-126 AR Shim, 30 x 48 x 1.10 mm0828-127 AR Shim, 30 x 48 x 1.15 mm

20 0832-083 X 1 Bearing21 0827-060 1 Nut22 0832-050 1 Bearing


42


MAGNETO ASSEMBLY0745-060

1 0802-042 1 Rotor/Flywheel2 0829-012 1 Key3 0827-010 1 Nut4 0826-102 3 Screw, Machine

5 0802-041 1 Stator - Assembly6 0831-064 1 Clamp7 8470-510 4 Screw, Machine


43


MAGNETO SIDE ENGINE COVERS0745-061

1 0806-107 X 1 Cover, Magneto2 0830-132 1 Gasket, Magneto Cover3 0832-010 1 Bearing4 0826-155 X 1 Plug, Check5 0830-015 1 Washer, Crush

6 0830-176 1 Seal, Cap7 0806-066 1 Cap, Magneto Cover8 8468-650 4 Screw, Machine9 8468-695 1 Screw, Machine

10 8468-665 3 Screw, Machine


44


CLUTCH SIDE ENGINE COVERS0742-232

1 0806-112 X 1 Cover, Outside2 0830-137 1 Gasket, Cover3 0806-110 X 1 Cover, Inside4 0806-109 X 1 Cover, Clutch5 0830-133 1 Gasket, Clutch Cover

6 8468-616 9 Screw, Machine7 8468-630 21 Screw, Machine8 0829-001 6 Pin, Dowel9 0830-013 1 Washer, Crush

10 8408-812 1 Screw, Cap

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

Printed in U.S.A. p/n 2258-950

2010 manual illustrated parts 1000 trv cruiser eft.pdf24 2506-955 1 bracket, backrest support. 2010...

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